ML20206N439

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Rev 8 to Procedure CPM-6.3, Preparation,Approval & Control of Operation Travelers
ML20206N439
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 04/02/1981
From:
BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML20206N354 List:
References
FOIA-86-270, FOIA-86-A-87 CPM-6.3, NUDOCS 8607010455
Download: ML20206N439 (15)
v • d • e


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. BROWN & ROOT, INC.

CPSES PROCEDURE k[O NUMBER REVISION EFQ[CTIVE Sh Q J08 35-1195 ~%

CPM-6.3 8 4/2/81 1 of 7 TITLE: ORIGINATOR:

V M dh PREPARATION, APPROVAL, DATE AND CONTROL OF OPERA- REVIEWED BY:

TION TRAVELERS

' / M c%d//8/

' / / , ) j JR CLA ,

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/ DATE V A//A' % V T .T!-8/

/ 'TUGCQAA DATE APPROVED BY hI- b' wM 4-/-7/

~ CONSTROCTION PROJECT MANAGER DATE o.i TABLE OF CONTENTS OCl/

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1.2 I"$0!f'"

SCOPE Bo#6 2.0 GENERAL

, \

2.1 RESPONSIBILITY

2.2 DESCRIPTION

OF AN OPERATION TRAVELER 2.2.1 General Traveler Information 3.0 k PROCEDURE

. 3.1 ,/

BASIC PREPARATION SEQUENCE 3

3.1.1 3.1.2 Traveler Development /

Traveler Content 3.1.3 Numbering Sequence -

3.1.4 Initiation Authority 3.1.5 Traveler Approval 3.1.6 Distribution of Travelers 3.2 TRAVELER CONTROL 3.3 TRAVELER REVISIONS AND CHANGES 3.3.1 Revision Preparation 3.3.2 Field Revisions For Non-ASME Related Travelers 4.0 SUPPORTING MATERIALS 4.1 AFFECTED DOCUMENTS o.ii LIST OF FIGURES Figure 1 CONSTRUCTION OPERATION TRAVELER Figure 2 CONSTRUCTION OPERATION TRAVELER CONTINUATION SHEET NOTE: Due to the extent of changes in issuing Revision 7, change bars normally appearing in the margin

,. have been omitted.

E607010455 860624 4

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AMAS tt.10E'/ SED JOB 35-1195 Comanche Peak Steam Elect'ric Statio6Ath Sheet 1 of 2 Construction Procedure 3 C0CUMENT CHANGE NOTICE NUMBER This notice applies to Construc' tion Procedure No. 35-1195 _ CPM 6.3 Revision 8 .

This change will be incorporated in the next revision of the procedure.

Change the procedure as follows:

Replace the following page with the attached:

Page 2 of 7 k

Reason for change: Additional Requirements This change approved by: Reviewed by:

Wrfgina tor

& //28/82_

'Cate

. A 'l'5U Brow Root Quality Assurance Date Rev 'by:

Reviewed by: # /  ?/

7GCO' QualT@ssurance / ' Date OG LJ,W/A 2-Z- W 2/3/82 Construction Project Maaager Date Effective Date f sm- 3_

      • Nme. O -e- > @m,, ,

ARM 3  ;

JOB 35-1195 b Comanche Peak Stea.1 Electric Statio -

Sheet 1 of 2 Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 2 This notice applies to Construction Procedure No. 35-1195- CPM 6.3 Revision 8 .

This change will be incorporated in the next revision of the procedure.

Change the procedure as follows:

Replace the following page with the attached:

} age 5 of 7 Reason for change: Change in requirement This change approved by: Reviewed by.

A41Z - hftQfj}d% l Z.-3& 8l _

l ~lN 2--

.Origina t01- Date Brop Root Quality Assurance Date Reviewed by:

Ass,r /-/8-SZ. Il15/82 Construction Project Manager Date Effective Date

ARMS INDEXE9 Comanche Peak Steam lectric Station D Sheet 1 of 2 Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 1 This notice applies to Construction Procedure No. 35-1195 CPM 6.3 Revision 8 .

This change will be incorporated in the next revision of the procedure.

Change the procedure as follows:

Replace the following page with the a+,tached:

Page 4 of 7 4

?

Reason for change: Change in requirement This change approved by: Reviewed by:

0r iginator NJ f**bl A, ,*,A L // W)

, Date Brown & Root'Q ity Assur'ance /0atd Reviewed by:

<( 6P/  !

Construction Project Manager /

[/[r/'

Ofte 11/16/81 Effective Date e

I .

i PROCEDURE EFFECTIVE

. ' BROWN & RQOT, INC, NUMBER REVISION DATE PAGE CPSES OB 35-1195 CPM 6.3 8' 4/2/81 2 of 7

1.0 INTRODUCTION

1.1 PURPOSE This procedure describes the preparation, approval and control of

' Operation Travelers used at CPSES to control activities. The Opera-

' tion Traveler provides sequential instructions on how to perform a task, identifies the required inspection points, and specifies the documentation for these activities. The specified sequence on the traveler should be followed; however, due to construction inter-ferences and other constraints, deviation from the sequence, with QA/QC concurrence, may be allowed. Additional controls in the form of supplementary instructions or other procedures, may be used to meet the applicable requirements.

1.2 SCOPE This procedure shall be used for safety-related and balanct-of-plant activities. However, references to QA/QC do not apply to balance-of-plant activities and those inspection functions shall be accomplished by other departments.

2. 0 GENERAL 2.1 RESPONSIBILITY Signature authority for initiation on an Operation Traveler shall oe either the Construction Superintendents .esponsible for the work or the discipline engineer responsible for technical guidance. The B&R Site QA Manager is responsible for monitoring the implementation of the system throuah the assignment of QC inspection points and consul-tation with the ANI for selection of ANI inspection points for ASME related activities, while TUGC0 QA is responsible for the assignment of QC inspection points for non-AStiE activities. jNeither QA/QC or Engineering review are required for travelers of a-repetitious hature that have a standard fonnat. When such reviews are not per-

, hormed, the initial traveler number shall be entered in the " Reviewed By" block. The initial traveler should hote the review waiver of subsequent travblers.

f Even though travelers of a repetitious nature do not require QA re-view of each individual trav0ler, ASME-related travelers of a

' repetitious nature shall be routed to QA so that ANI review may be performed on each indi'vidual traveler.

The Operation Traveler (Figures 6.3-1 and 6.3-2) serves as a fabri-cation / installation / inspection checklist of operations necessary to achieve a quality end product. Accordingly, the checklist details will vary depending on the complexity of the operation.

w 3.- ,

CPM 6.3 Rev. 8 DCN f3 '---~ ~

2/3/82' Sheet 2 of 2

PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CPM-6.3 8 4/2/81 3 of 7 2.2.1 General Traveler Information General information normally included on the Operation Traveler is as follows:

1. Part, serial, or tag number and material description (s),

where applicable. -

2. The department assigned the task to perform operation (s).
3. "hu m0p'mber and revision and other information as require

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th~essfully co'mplete the operation in accordance with applicable fequirements. Examination or test procedure / instruction numb-ers and revisions shall also be recorded on the traveler or supp-lementing report for examintation or testing activities.

4. All dimen:. ions and tolerances necessary to assure compliance with applicable design drawings and specifications. This in-formation may be given by reference, provided persons perform-ing the work have access to the referenced material.
5. Any needed offsite operations or processing is cited in the appropriate sequence with all other operation.
6. Necessary instructions for handling, cleaning, storing and preserving items.
7. Required QC/ANI inspection, hold, or witness points, as applicable.

3.0 PROCEDURE 3.1 BASIC PREPARATION SEQUENCE 3.1.1 Traveler Development

[he operation sequence and necessary detailed information on the

, traveler should be developed among the responsible construction personnel, the Discipline Engineers providing the technical

' guidance, and the Quality Engineers responsible for the ' quality Irequirements. 'The' Discipline Engineers or construction personnel initiating the traveler shall obtain Westinghouse approval if the traveler involves NSSS equipment.

3.1.2 Traveler Content Jhetravelerpackageshallcontajh,orpiayrefer'ence'ifnormally available, manuals the drawings

/ guidelines, .etc'/,, procedures, necessary to instructions, accomplish the manufacturer's activity. '

ISSUE BROWN & ROOT, INC.- NUMBER REVISION DATE PAGE CPSES '

JOB 35-1195 CPM 6.3 8 4/2/81 4 of 7 3.1.3 Numbering Sequence ,

The controlling organization shall assign the number to the tra-veler and provide records showing to whom the traveler was issued; and maintain records to indicate a history of all travelers generated and the activity covered by the travelers.

The traveler numbering system is shown in the following example:

"MP90-001-02-5000" MP = Identification letters representing the craf t department or engineering discipline originating the traveler.

90 = The calendar year in which the Traveler was written.

001 = The individual sequence number identifying a parti-cular Traveler.

02 = Unit number may be included, but is not required.

5000 = Ihe turnover (start-up) system number for the acti-vity described on the Traveler.

4 3.1.4 Initiation Authority Travelers may be initiated by Engineering disciplines or Con-struction Superintendents.

3.1.5 Traveler Approval QA shall review and approve the Traveler by signing the " Reviewed l By" block.

3.1.6 Distribution of Travelers After review by QA/ANI, as applicable, the traveler is returned to the controlling organization for recording and distribution.

3 '. 2 TRAVELER CONTROL Traveler packages shall be issued to craft personnel as they are needed for work. The traveler package shall remain in the work area until the work has been completed and accepted by QA/QC or until the end of the shift, wh.ichever is first.

Travelers shall be completely' maintained throughout the construction process. Each complete operation requires the initials and date of the person completing the task. This shall be accomplished at the completion of each operation and prior to moving parts or assemblies to the next scheduled operation.

U CPM 6.3 Rev. 8 DCN #1 11/16/81 Sheet 2 of 2

PROCEDURE EFFECTIVE

. BROWN & ROOT, INC.

NUMBER REVISION DATE CPSES PAGE

  • i l 1-JOB 35-1195 l l CPM 6.3 f 8 4/2/81 5 of 7 All identified hold points shall be honored and work shall not proceed beyond that point until acceptance of the hold point is shown by the QA/QC/ANI representative's signature / initials, as applicable, and date opposite the hold point. The results of the QA/QC inspection shall be recorded in the QA/QC Eng column.

Upon completion of all the steps listed on the Traveler, the Traveler shall be returned to the controlling organization for further pro-cessing, as required. ASME completed travelers shall be forwarded to B&R QA while non-ASMC completed travelers shall be forwarded to TUGC0 QA for review and subsequent filing in the Permanent Plant Records Vault. Travelers governing non-Q activities shall be for-warded to the B0P office for maintenance.

3.3 TRAVELER REVISIONS AND CHANGES 3.3.1 Revision Preparation All changes, regardless of their significance, must be documented on the traveler, indicating the operations affected, description of the change, and QA/QC's concurrence. The revision number and a description of the change will be noted below the last traveler operation, or on a continuation sheet. The item being changed shall reference the user to the described change.

3.3.2 Field Revisions for Non-ASME Related Travelers Where it is not feasible or practical to route the traveler revision, the QA/QC Representative in the field who is familiar l with the task being performed may approve a revision to the tra-veler provided the following provisions are met:

1.

The revision is not a significant departure from the original concept;

2. The responsible Quality Engineer is made aware of this re-vision at the first available opportunity by the QA/QC rep-resentative;
3. The revision is signed by the responsible Construction Super-intendent, or responsible engineer.

The QA/QC representative initials and dates the traveler showing approval of the revision described above.

CPM 6.3 Rev. 8 DCN #2 D-f- -..

1/15/82 Sheet 2 of 2

  • PROCEDURE EFFECTIVE BROWN & ROOT, INC, NUMBER REVISION DATE PAGE CPSES- ' ' -

JOB 35-1195 CPM-6.3 8 4/2/81 6 of 7 FIGURE 6.3-1 CONSTRUCTION OPERATION TRAVELER CONSTRUCTICN CPERATICN TR AVELER IS-IIS S ECUIPMCef NC, UNIT N4 CVANTITY hTRAVELERNO. paat_CP_

@ ACTIVITT DESCRIPTICM hREFERENCE CRAWING3 LOCATiCN 5T3 TEM

@!PEC/ Pet 0C/EM.3N57R.

PREPAREDSY OATE O C PT.

REVtCWCD 8Y CATE ANI REVIEW OATE

- A/CC CP eNL CEFT. C#CRaflC4 E"E ' A"'

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PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES -

JOB 35-1195 CPM-6.3 8 4/2/81 7 of 7 FIGURE 6.3-2 ,

CONSTRUCTION OPERATION TRAVELER CONTINUATION CONSTRUCTION CPERATION TRAVELER CONTINUATION

  • TleavtLER NQ ACTIYrTY OCSCRIPTION GE _ cf _

.PREPARC08Y CATE ftCYtCwt3 SY

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ANI REVIEW DATE.

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OlmsAi"e01 @ EQUIP, N O.

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hNcNca9 Me@ ann Assemblies Installation h REqNg[DPW'"SS OsS OC/ ENG. lNSTR. Os LOCATION

-12 m v Oio SYS. TEM Safeguard Building 790'6" v 9301 PREPARED BY- M 'Ith DATE / 7 (' ~ U DEPT. Nu W REVIEWED BY / MM DATE /24 Mr/

ANI REVIEW M/A DATE oP.No DEPT.

QA/QC OPERATION cONSTR ENG. ANI NOTE #1: a) Dwgs. received under CP-460 b) GaH Spec. 2323-ES-100, & 2323-ES-12 c) Amphenol Sams Documents 123-2101 & 123-2098. Install-ation operation and maintenance instruction manual.

d) Amphenol Sams Document 123-2245 Rev. A.

H3TE #2: An asterisk (*) indicates a QC hold point. Do not proceed without QC acceptance of operation.

tiOTE #3: Storage and maintenance requirements as described in the Equipment Maintenance Record shall be enforced uritil Opera-tion No. "5C" of this traveler is performed.

,  !!0TE #4: It is not necessary for not-related operations to follow a progressive sequential order.

1 Elect Select the correct penetration assembly by utilizing the tag number shown on the name plate which is located on the header plate.

egg 4 OC(V)  !!0TE: Unit #1 E.P.A.'s will have a tag number such as 1E-48 and j Unit #2 E.P.A.'s will have a tag number such as 2E-48.

l Location of the penetration assemblies.shall be determined by using the latest construction issue of drawings.

4

2 Elect Unpacking Electrical Penetration

')C(V) CAUTI0il: Extreme caution shall be used in dismantling the crate.

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Pry the crate apart instead of using a hammer,.s.oias t'o /k///g Y avoid damage to equipment inside. Do. not' usethe ehuip-ment as a levering device. Y,s N

2a Elect If a framework exists, dismantle it being extrembl QC(V) avoiddamagingthewiringortheassemblyinside.'[t,' ,

cautious askto g h' D-25 Elect Remove the plastic protective cover. '

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QC(V) / fp ,

2c Elect At this time, unbolt the header platr. from the cradle which it is QC(V) resting on. //lrW 4 LIOTE: Studs, nuts and washers used to secure all E.P.A.'s to the ,

cradle are not to be thrown away. These items are to be ussd $/i in attaching the header plate to the weld neck flange. ///7/  %

ARMS '

EH../. ff L INDEXED g

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. . . . . . . .. ...... ..-....n..v.o TRIVELER 'NO. ACTIVITY DESCRIPTION Electrical Penetration Assemblies Installation EE-81'- 193-9'301 g 5 b S [ M f' PREPARED BY OATE / 2 -/F N REVIEWED BY /M' TeJxe.48 OATE /2 //o /P/

ANI REVIEW M DATE oP.No. DEPT. QA/oc OPERATION CoNSTR ENG. ANi 2d Elect Support rods and support plates are assembled to the header plate on all penetration assemblies by the supplier prior to shipment.

b d /J QC(V) Check that all support rods are securely threaded into the header /j,M/ jf, plate. Check all hex nuts to make sure they are tight. (Tighten as necessary).

2e Elect All cable ends shall be sealed by using Heat Shrinkable end caps or scotch tape 33 (or equal) tape to prevent entrance of moisture. [/4

/7 QC(V) Visually check all cables for damage to the in tuh tica which might have occured during shipment.

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  1. ff%ldg 3a Elect Wipe raised face of flange with clean non-abrasive rag saturated with commercial Methyl Ethyl Ketone (MEK), rub vigorously and allow QC(V) to dry. fg'/ //g(/ / p, CAUTION: Do not allow smoking or open flames in the area while usin g 9 MEK.

3b Elect Thoroughly wash raised surface of flange using tap water and a clean non-abrasive rag. Rub vigorously to remove all traces of rust p J QC(V) inhibitor and wipe clean. Remove all traces of rust, if any is found per traveler EE79-033-G200. II fp/gj

///

i 3c Elect Using a clean non-abrasive cloth, clean the raised sealing surface j ~

with 1% sodium Hydroxide (Na0H) solution. <

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QC(V) CAUTION: Do not allow solution to contact the primed or painted g7///g li/R surfaces. Operator must wear gloves (vinyl perferred) and splash proof safety glasses.

3d Elect Thoroughly rinse surface with tap water and immediately wipe dry.

QC(V) 7 i,

i 3e Elect Immediately clean surface with an isopropanol saturated clean soft

( QC(V) clcth. f 17/fh 3f Elect Allow to dry for 20 minutes. Inspect for any evidence of moisture,. /gll71 '

QC(V) dust, etc. Surface must be clean and dry, g

39 Elect Coat raised surface with Dow Corning 971V lubricant. C' i/0 El

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QC(V)

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- g j NOTE: Weld neck flange is now ready to accept .he pRnetra' tion' I)y, assembly.

4 Elect Electrical Penetration Assembly Installation \

QC(V) CAUTION: Use care when uncoiling cables. Donotpb,ilagainstthe ~

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module tenninations in order to minimize t ~ amount..of tension and strain on the module terminatio 'bles f f/7 i must be supported at all times.

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TRAVELER NO. ACTIVITY DESCRIPTION EE-81-IB-9301 m Elect rical Penet ratinn Auombline incta11794nn PAGE l. OF 5.

PREPARED BY b TOk V DATE / 2 -/#4/

REVIEWED BY /*' Iair#>u EO DATE /1//0/W ANI REVIEW A-) d DATE QA/QC OP. NO. DEPT. OPE. RATION CONSTR ENG. ANI:

NOTE: The loose equipment kit packed with each electrical penetra-tion will contain materials for the installation. The Dow Corning 971V lubricant is located in electrical penetration crate #2E-32. These 8 oz. containers should be sufficient for both Unit #1 & #2 installation.

4a Elect Pass the two (2) large 0-ring seals over the inboard cables up to th inboard side of the header plate.

QC(V)

[/Y//f/ #//Q 4b Elect Attach hoist hooks to factory eyebolts and raise the entire penetra-tion assembly and the fixture to the nozzle location. If adequate space above penetration will not allow use of hoist, transfer pene-tration to carriage and use carriage for support and location of QC(V) penetration during installation.

CAUTION: The inboard cable support fixture is attached to the heade r g g plate and must be fully supported at all times. '#

//pf / z NOTE: If gauge reads zero (0) Electrical Engineering. Do not proceed.

4c Elect Maneuver the penetration assembly to a location where the cables can

, feed into the nozzle.

y QC(V) NOTE: Some penetrations may require rotation of gauges to aid in installation of penetration assembly through nozzle.

k j ff, '#/,/gf Elect Feed the inboard cables from the tank exterior.

4d QC(M) p jf7 /

. 4e Elect Depressurize the penetration assembly by removing the screw and sealing washer located between the 0-ring grooves, as required by s /,,

QC(V) caution tag.

@fp '7'f4 4f Elect Clean the header plate face on the o-ring groove, side with a lint free, non-abrasive cloth using commerical grade Methyl Ethyl Ke e ,

(MEK) in order to remove all foreign substance and allow t QC(V) CAUTION: Do not allow smoking or open flames in the a

/

,,,/'k #p using HEK. .ca 7 Elect Wipe the 0-ring seals with a clean cloth and co t 49 g,L' 49 'h'afMghtiff1m of Dow Corning 971V lubricant and place the 0-ri s jnf4their #appo-QC(V) priate grooves in the header plate. g Kg p ,

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- . . . . c. - . . w . s - .i . a. . . . m :. . : . . .x : m u v. s e e n TR'AVELER NO. ACTIVITY DESCRIPTION EE-81-//jS-9301 m Electrical Penetration Assemblies Installation 5 PAGE _4_ OF_,

PREPARED BY- [A l'O >P DATE / L M '~ F/  !

REVIEWED BY #M' ~7-~ DATE / 2 //o /N ANI REVIEW /t)A DATE cA/oc OP. NS. DEPT. OPERATION CONSTR ENG. AN 4h Elect Continue to feed the assembly into the nozzle until the header plate QC(V) makes contact with the flange face. f h'jjpf */lfg(

4i Elect QC(V)

Prior to contact, check for correct placement of the two (2) 0-rings.p CAUTION: Be extremely careful not to dent or nick flange face or th  %

f header plate face. In mating the header plate and the wel ep////a l neck flange, make sure open bolt holes line up.

4j Elect Install all studs in the bolt holes and add nuts and washers. Tightch QC(V) nuts finger tight until all are installed.

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4k Elect Tighten all nuts using a " diametrically opposite" sequence to an QC(V) initial torque of approximately 25 ft lbs. g g /#/

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Elect Tighten all nuts using a " diametrically opposite" sequence to an 41 QC(V) final torque of -10) ft lbs.

g Torque wrench # 100(+10,97f C f -- /

Cal, due date t'Y DS l'fff 6' /M M kgj y

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,y y,) 22- n/n/'gj 4m '.l ec t Field shall provide some type of mechanism to support the cables on both sides of the vessel wall. Refer to caution note under itea 5.

QC(V) Field shall also provide a method of enclosing both ends of assembly /#

for protection against damage during construction. /

/7f 4n Elect Remove hoist hook from eyebolt and any other rigging equipment with care so as not to strike the valves or gauge or other components. p QC(V)? OTE: Repack the loose equipment kit with the unused material and ',/

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seal the carton with tape. Write the corresponding E.P.A. 8) tag number on all cartons and fill out a reutrn to warehouse form attention Carl Parr.

5 Elect Condensation Removal /Repressurization QC(V)

Immediately after E.P.A. is completely installed perform the following:  %/ \

gj Remove the 1/4 inch pipe plug from the outer surface of the header plate. $/gj Sb Elect Purge the system thoroughly with 10-15 psig dry nitrogeh for a p hfA .pr){

QC(V) minimum of 30 seconds to assure removal of condensation \ g j Dry nitrogen utilized for pressurizing the penitration NOTE: 4 g assemblies shall be dew point of -76 F. \-

Sc Elect Reclose the two gauge valves and replace plug. \

oc(v) NOTE: When replacing threaded fittings, gauges, or valves, a thread g sealant such Newington, Conn. asor"equivalent Loctite" number shall be used. 222 by Loctite Corppration, %g/

Sd Elect Pressurize assembly to 45 psig with dry nitrogen (Dew point -76 ).

QC(V)

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  • TRAVEL.ER NO. ACTIVITY DESCRIPTION

. EE-8)-193-9301 Electrical Penetration Assemblies Installation PAGE _5 of f i l PREPARED BY ( A ) b- W DATE / 2. - / o " P/

i REVIEWED BY /' M ' h r> c e O DATE / 2. /d F/

ANI REVIEW MN DATE t

IOP. NO. OEPT. QA/QC OPERATION CONSTR ENG. AN1-Se Elect Perform a leak rate test in accordance with procedure EEI-9.

! QC(V) #

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' 5f E's ect Record all data and submit to Electrical Engineering. <

W QC(V) '

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Sg E;ect After completion of leak rate test repressurize the penetration V f 7f, QC(V) assembly to 60 psig. '/

Sh Elect From this point on the Electrical Penetration Assemblies shall be QC(V) maintained in accordance with the equipment maintenance record.

M//2 Af ter completion of this Traveler return to the Electrical Engineerir g Department, attention Bill Ross.

Upon Engineering review, issue to Quality Engineering. /#

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